CONCRETE PAVEMENT DESIGN

OVERSEAS ROAD NOTE 29 (ORN 29)

STRUCTURAL DESIGN
Commercial vehicles + their axle loading (Vehicles with unladen weight 3 tonnes and
above)
Passenger cars are considered to have negligible structural distress on the road
pavement. However these are considered in the traffic flow, junction design , number
of lanes,
Convert the number of commercial vehicles into the number of equivalent equivalent
standard axle loads (8.2 tonnes).
This information (data) can be obtained from traffic count. Commercial vehicles/ -
categorized into various loaded tonnage
If this is not available or for new developments/expansions. Road Note 29 provides a
guide on estimation of commercial vehicles for various road types.
 From these, one can estimate the cumulative standard axle loads over the design life
based on growth rate.
Road Note 29 gives curves up to 40 years design life at 3%, 4%, 5%, and 6% growth
rate.

DESIGN OF CONCRETE PAVEMENTS

Traffic Loading
Commercial vehicles/day
Axle loading – standard axle load
Growth rate (traffic)
Design life
Cumulative standard axle loading to be used for structural design based on subgrade
strength

Subgrade
Road Note 29 classifies subgrades into three classes (Table 5)
Table 5:
Minimum Thickness of
Type of Subgrade Definition Based on CBR
Required Subbase
Weak CBR ≤ 2% 150 mm
Normal 2% < CBR < 15% 80 mm
Very Stable CBR ≥ 15% 0
Drainage Requirements
Water Table should be prevented from rising to within 60 cm of the formation level.
1) By provision of drainage system
2) Raised embankment

Subbase Thickness
Based on the subgrade strength.
Table 5 gives the minimum subbase thickness.
These are suitable where no construction traffic is going to use the road.
Where construction traffic is going to use the prepared subbase prior to placement of
concrete (on weaker or normal subgrade classes) the subgrade should be strengthened.
1) For subgrades with CBR ≤ 4% - Additional 150 mm layer which meets
subbase requirements (topping layer).
2) For all other normal subgrade 4% < CBR ≤ 15% - Additional 80 mm topping
layer can be used

CONCRETE SLAB
Figure 11 gives the thicknesses required for reinforced and unreinforced slabs in terms
of cumulative number of standard axles to be carried for the three classes on subgrade
in Table 5.
o The thickness to be rounded upward to the next 10 mm intercept
o The design is based on a minimum crushing strength of concrete of 28 MN/m2
(28 N/mm2) at 28 days using Ordinary Portland Cement.
o On residential roads built for light traffic the alternative design thickness
(Figure 11) should be used to cater for heany loads associated with
construction of surrounding development.
o Figure 11 gives slab thicknesses for normal subgrade (2 < CBR < 15)
 For CBR ≥ 15% slab thickness can be reduced by 25 mm.
 For CBR ≤ 2% slab thickness should be increased by 25 mm.
 Dotted lines give slab thickness of unreinforced concrete where heavy
traffic loads with light (density) are expected.
REINFORCEMENT
For reinforcement concrete, the minimum weight of reinforcement in relation to the
cumulative number of standard axles is given in Figure 12 in terms of:
o Weight of long mesh reinforcement
o Area of steel per unit width of pavement
 Eg. For standard axles number (CESAL) of 2.0 x 106
 Weight of reinforcement = 180 mm (Figure 11)
 Weight of reinforcement = 300 mm2/m width of slab (Figure
12)
Concrete Cover
A minimum of 60 mm for slabs ≥ 150 mm
A minimum of 50 mm for slabs < 150 mm
Reinforcements should terminate at least 40 mm and not more than 80 mm from the
edge of the slab and from the joint.
The transverse reinforcement by 8 mm Ø at 200 mm spacing
At the transverse overlap of reinforcement mat (mesh), the last transverse wire of one
mat should be within the last complete mesh of the previous mat and the overlap
should not be less than 450 mm.
Spacing depends on bar diameter

Overlap ≥ 450 mm
 When deformed bars are used the overlap should not be less than 40 Bar Diameter

40Ø

PAVEMENT JOINTS
Temperature changes cause expansion or contraction of solid slabs
If the slab is cooled, it will tend to contract and if the contraction is constrained,
tensile stresses will be induced which may cause cracking of the slab.
Likewise if the slab heats up it will tend to expand and if the expansion is restricted,
compressive stresses will be induced which also cause cracking or warping of the slab.
One method to counteract these defects is the introduction of joints, spaced in such a
manner to relieve these stresses. Reinforcements can also be used to minimize the
defects by increasing the capability of the slab to sustain the induced stresses.

Types of Joints
Contraction joint
Expansion joint
Construction joint
Hinge or warping joint

Joint Requirements
Discontinuity to release stresses
Sustain the load transfer mechanism
Seal against water

Contraction Joints
These are transverse joints intended to release slab from the tensile stresses.
A groove is cut or formed at the pavement surface to make certain that cracking will
occur at this location
Load transfer at this joint is attained by grain interlock of the cracked surface.
If reinforcement is used (RC slab) the spacing of contraction joints may be increased
 For longer spacings, dowels are required across the transverse joint because the joint
will open wider and therefore load transfer by grain interlock may be doubtful.
The groove can be formed by sawing or by placing a metal or fibre strip in the uncured
concrete and then removing prior to hardening of the concrete.
Apply sealing material (bituminous material)

Expansion Joints
Has to allow free expansion of the solid slab.
Are constructed with a clear break throughout the depth of the slab to permit
expansion to take place
Since the joint has no aggregate interlock, dowel bars are used for load transfer.
The dowel bars has to be smooth (lubricated) on one end to allow free movement.
An expansion cap has to be provided at the end of the dowel bar on the smooth side.
However, it should be noted that expansion joints for highways are likely to suffer
from pumping effect by traffic load.

It is essential to seal the joint periodically to prevent water from infiltrating into
interlaying pavement layers. This is best done during cold season when the joint is at
its maximum opening.

Construction Joints
Used as a transition from old to new concrete construction such as the case for end of
day’s work.
These may take the form of :
o A butt joint (most common)
Deformed Bar (Ribbed)
Direction of Construction
 o A keyed joint

Hinge or warping Joints

Used in unreinforced concrete construction to relieve stresses due to both warping
movements and contraction in order to prevent cracking
Vertical temperature gradient in the slab is likely to create warping movements.
The type of joint depends on primarily the method of construction and method of
pouring the concrete.
If a–lane–at–a–time of construction is used, keyed joints are generally adopted with an
option of using tie bars for proper load transfer

If two – lane construction is used, the most convenient type of longitudinal warping
joint is dummy – groove type with a dowel tie bar.
 SPACING OF JOINTS IN REINFORCED CONCRETE SLABS
Road Note 29
Figure 13 shows the recommended maximum joint spacing in relation to the weight of
reinforcements.
The maximum joint spacing used in design should correspond to the actual weight of
reinforcement used and not necessarily to the minimum weight of reinforcement
required.
Every third joint should be an expansion joint, the remainder contraction joints

E C C E

When soft aggregates such as limestone are used, the joint spacing can be increased by
20%.
Reinforcements should be discontinuous across the joints.
Longitudinal joints should be provided such that the maximum slab width is within 4.5
m except where special reinforcements are used.

SPACING OF JOINTS IN UNREINFORCED CONCRETE SLABS

Maximum spacing of expansion joints
o 60 m for slabs ≥ 200 mm thickness
o 40 m for slabs < 200 mm thickness
In addition, intermediate contraction joints at 5 m intervals where aggregates other
than limestone are used.
For limestone aggregates, expansion joints spacing can be increased to 72 m and 48 m
(20% increase) with intermediate contraction joints at spacing of 6 m.
Tied warping joints may be substituted for some of the solid contraction joints.
Longitudinal joints should also be provided such that the maximum slab width is
limited to 4.5 m.
Example
A Reinforced Concrete slab is required for 2376 cv/day (sum in both directions) at the
end of construction. The traffic growth rate is estimated to be 5% per annum. The soil
is clay with LL of 65% and PL of 25% with water table at 500 mm below the finished
road level (Subgrade CBR = 2%). Design life is 20 years. Determine slab thickness,
reinforcement requirements and joint spacing requirement.
Solution
For
o 1188 cv/day (one direction)
o 5% growth rate
o 20 years design life
(1 + 𝑟)𝑛 − 1
𝐶𝑢𝑚𝑢𝑙𝑎𝑡𝑖𝑣𝑒 𝑐𝑜𝑚𝑚𝑒𝑟𝑐𝑖𝑎𝑙 𝑣𝑒ℎ𝑖𝑐𝑙𝑒𝑠 = 𝑃 𝑥 [ ] 𝑥 365
𝑟

(1 + 0.05)20 − 1
= 1188 𝑥 [ ] 𝑥 365 = 𝟏𝟒. 𝟑𝟒 𝒙 𝟏𝟎𝟔
0.05

o Cumulative standard axle loads

 Table 2: Conversion factor = 1.08
o Cumulative standard axle loads (CESAL) = 14.34 x 106 x 1.08
= 15.49 x 106
Subbase Thickness
o Table 5: For Subgrade of CBR = 2% (Weak) – Subbase Thickness = 150 mm

Slab Thickness
o Standard Axle = 15.49 x 106 – Slab Thickness = 230 mm (Figure 11)
o Slab Thickness = 230 + 25 = 255 mm (Since Subgrade CBR ≤ 2%)

Reinforcements Requirements
o Weight or Reinforcements = 3.9 kg/m2 (Approximately 4.kg/m2) (Figure 12)

Joint Spacing Requirements

o Joint Spacing = 25 m (Figure 13) – Expansion joint 75 mm with 2
contraction joints in between
Table 6: Dimensions of Sealing Materials and Groove in Concrete Slab
Type of Spacing Width of Groove Depth of Seal
Joint (m) (mm) (mm)
<8 10 20 – 25
Contraction 8 – 15 15 20 – 25
Joint 15 – 20 20 25 – 30
> 20 * 25 – 30
Expansion 5 mm greater than
All 25 – 30
Joint thickness of filler
Warping
All 10 15 – 20
Joint
Longitudinal
- 5 25 – 30
Joint
* For Spacing > 20m, width of the groove should be increased by
5mm each 5m spacing in excess of 20m

Groove Thickness

Seal
Depth of Seal

Table 7: Dimensions of Dowel Bars

Slab Thickness Expansion Joints Contraction Joints
Bar Ø (mm) Bar Length Bar Ø (mm) Bar Length
(mm) (mm)
< 150 Not Rec. Not Rec. Not Rec. Not Rec.
150 – 180 20 550 12 400
190 – 230 25 650 20 500
> 240 32 750 25 600
Dowels should be placed at 300mm, centers. Half of the length should be coated with
bond breaking compound.
Longitudinal joints should have tie bars, 12 mm Ø by 1m long at 600mm centers
except in case of roads < 0.15 Million Standard Axles.